Fireproof material.



'JKEIZO SAKURAI, or SAN FRANCISCO, CALIFORNIA.

FmEPRooF MATERIAL.-

' Specification of Letters Patent.

Patented May 7,1907.

Ayplioiition mid April 5, 1906. Serial in. 310,023.

To all whom; Lt may concern:

Be it known that I, KEIZO SAKURAI, a citizen of Japan, residingin thecity and county of San Francisco and State of California, have inventednew and useful Improvements .in Fireproof l\laterials, of which thefollowing is a specification.

My invention relates to the manufacture of brick and its object is tomake a cheap and perfect lire-brick from certain materials whichheretofore have not been deemed. capable of use in combination for thepurpose.

The invention broadly comprehends the mixing of a suitable vehicle aschrome iron ore, magnesiw, sand, infusorial or diatomaeeous 'earth,eteetera, with an easily fusible binding material, subjecting thismixture to a suitable high pressureand baking at a suitable temperature;l

it is usual in the manufacture of fire-brick to employ fire clay as abinder; the fire clay being comparatively pure and containing verylittle alkaline and metallic oXid.

It has not been deemed possible heretof ore to make fire-brick with aneasily fusible binder, such as common clay. But I have discovered that Ican produce a good, cheap, commercial fire-brick, if the originalrefractory material is first reduced to two forms, one a coarse granularmass'and-the' other a fine powder, and then suitable proportions of thecoarse and fine stufi aretaken and mixed with a suitable proportion ofcommon clay or other easily fusible binder, molded under very highpressure and then baked at suitable temperature. Conversely I am able totake clay containing too great a proportion of binding or fusiblematerlal to make perfect fire-brick andrender'it available,v by theadmixture in suitable manner some high refractory material likekaolin,'infusorial or diatomaceous earth, powdered sand, or the like,which will do no harm to the clay when baked. Also I have discoveredthat if bricks are made with infusorial or diatomaceous earth,

or argillaceous material having high refracture-bake like other I irebricks: the temperature is only enough to fuse the binder and the amountof binder is limited to just enough to bind permanently the particlesinto a coherent resistant mass, (2-)) They are capable of successfullywithstanding sudden heating and cooling. (4) They do not eontraet orexpand unduly when heated to high temperature, and do .not crack.

ln practicing the invention there are many binders suitable for thepurpose, such for example as alkaline and metallic oxids and silica, oralkaline silicate and metallic silicate; and these may be used eithersingly or in combination; but I. prefer an easily fusible clay binder.

The high pressure to which the mixture is submitted before baking ismost essential, as without it 1 do not get the desired results. Thepressure must be such as apparently to Weld the particles into acohesive mass.

The following formulae show the application of the invention, andindicate its variations:

(1) To make brick from chrome iron ore. Coarse granular chrome(20 to 30mesh) 50%,

fine powdered chrome (150 to 200 mesh) 7 40%, easily fusible binder asclay, 10%, sufficient water to render plastic, press at 5,000 to 6,000lbs. per sq. in., bake until the binder is vitrified 1,000 to 1,200 C.more or less.

(2) To make brick from magnesite: First remove 00 or other vaporizablcingredients from the magnesite by baking at high heat (not less than1,500 C. and sometimes 2,000 C. or more). Most magnesiteore containsmore or less silica which causes the material tov contract with hightemperature. It -is therefore necessary, or at least desirable, to bakethe magnesite containing silica to a higher temperature than the temerature which the finished brick in its uses w ll likely be subjectedto. Then take of this suitably baked granulated magnesite to mesh) tobaked powdered magnesite (150 to 200 mesh) 40%, easily fusible clay 15%to 20%, sufficient water to render plastic, press to 4,000 to 5,000lbsper sq. inch and dry; bake till binder melts at 1,000 to 1,200 C;more or less.

(3) To make fire-bricks from sand. Pure granulated sand (20 to 30 mesh)45% to powdered sand or infusorial or diatomaceous earth (150 to 200mesh) 40%, easily fusible clay 10% to 15% sufficient waterto renderplastic; press: at 5,000 to 6,000 lbs. per

. 1 sq. in.; bake until the binder melts at l,000 to 1,200 C., more orless.

(4) To make fire brick from infu'sorial or dintomacoous earth as avehicle. high lire refrzwtory infusorial or diatomaceous earth (which isa powder) 80%, fusible clay suitable water to render the mass plastic;press at 4,000 to 5,000 lbs, per sq. in. Bake as before. (12) ll thevehicle has any considerable tendency to expand or contract takepurecoarsesmld (20 to mesh) infusororial or diatonlacemls earth 30%, fusibleclay 20%, water to make plasticressure at. 4,000 to 5,000 lbs. per sq.in. 1321 e as before. (0) 1f the vehicle contains any organic matter orother vaporizable ingredients which have a tendency to expand orcontract in baking, first remove this injurious matter by baking atsuitable heat. .(This baking has the effect of uniting the powderedparticles ofcertain qualities of diatomaceous infusorial earth, such forexample as contains calcium 'or iron, and this must be ground up beforeusing). Coarse baked infusorial or diatomaceous earth (20 to 30 mesh)50% powdered baked infusorial or diatomaceous earth (150 to 200 mesh)30%, fusible clay 20%, water to make plastic, pressure at 4,000 to 5,000lbs. per sq. in., bake as before;

Having thus described my invention, what I claim and desire to secure byLetters Patent, 1s

1. A fire refractory material comprising a .refractory vehicle in twoforms, one a coarse granular mass and the other a fine powder,

suitable proportions of this fine and coarse stuff being mixed with asuitable proportion of an easily fusible binder and water, subjected tohigh pressure and baked.

(a) Take 2. A new article of manufacture consisting of-baked granulatedmagnes1te, baked powder magnesi'taeasily fusible cla andwater, subjectedto a high pressure, an baked.

3. A process of producing a fire refractory material, which comprisesheating a suitable refractoryfinedium containing vaporizable ingredientsto a point sufficientto remove I said ingredients and reducing thisheated refractory medlum to two forms, one a coarse granular mass andthe other a fine powder,

taking suitable proportions of the coarse perature sufficient only tofuse the clay and bind the particles together.

5. A fire-proof material comprislng approximately 40% of a coarsegranular fireform, approximately 150 to 200 mesh, approximately 20% ofan easily fusible binder and sufficient water to make a paste, saidpaste subjected 'to alpressure of approximately 5,000 pounds to thesquare inch, and

this pressed product bakedto approximately 1,000 O.

In testimony whereof I have hereunto set my hand in presence of twosubscribing witnesses. v KEIZO SAKURAI.

Witnesses 7 WM. J. GoRMAN, D. B. RICHARDS.

proof vehicle, approximately-20 to 30 mesh, approximately 40% of thesame in powdered

